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WIP ARC Trooper Echo

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TrooperTim1138 ()

Joined: 10 Sep 2017
Posts: 2
Location: Beaverton, OR
Medals: None

PostPosted: Wed Mar 07, 2018 8:18 am    Post subject: WIP ARC Trooper Echo Reply with quote

And here we go! I have started my build and have been maintaining a WIP thread on both the Clonetroopers Detachment and the Cloud City/Kashyyyk Base forums and thought I should be maintaining one here as well! What follows i where I am currently at:
3/4/18 Shopping! Yesterday I hit Home Depot for a few items. I wanted to make sure the bondo and the primer I picked up are OK?

Then on to the work on the helmet itself. I used the drill bit to "cut" between the holes I drilled around the edge of the visor (not recommended) and although I was able to preserve the outside face of the helmet, I believe I mangled the inside face a bit where the visor would actually be flush with the inside opening. This became even more apparent when sanding the edge of the visor area and the teeth. I assume it's quite important for this inside face to be smooth so it's flush with the visor when it's installed so as to create a clean line against the visor. There seems to be quite a variation in thickness around the visor area.

After removing the major areas left at the edge with the sanding drum on my dremel, I did the sanding mostly with 180 grit sand paper wrapped around short flat paint sticks.. The corners and teeth holes were all done with the needle files. It was helpful to have a variety of sizes and shapes. My plan is to sand the inside of the helmet around the edges of the openings to get a uniform thickness and repair the inside edge with bondo and re-sand (once the this first set of sanding is done).

In thinking about using bondo for the first time on this project I was wondering if it would be a good idea to fill the cavity created by the fin on the dome with bondo to strengthen it?

3/6/18 I think I may have figured out why part of my inside edges seemed so mangled around the visor area. On the inside the material actually flares up near the edges. I am not sure what the correct solution would be to correct this. One option would be to fill the low areas up to the flared edges and then sand out. The next would be to sand off the flared edges making the areas around the visor all the same thickness. I am not sure! The picture here doesn't do the best job of showing the flared edge I am talking about.

Throwing some bondo at this project is next on my list! Going to wash all the dust off the helmet tonight. Might not get to the bondo until next week, my respirator is elsewhere and I need to be able to let it sit in well ventilated area even after the sanding is done (not in my apartment). While I was thinking about bondo I noticed a small hole where I could see daylight peeking through in the right ear cap where the RF would attach. The material is thin there and I would be afraid that the weight of RF would break the surrounding material. I am guessing I should build up the area on the inside with bondo so it's a little more solid before I drill the hole for the RF so the washer and the RF mount have something more solid to grab onto? I thought at first the whole circular area there was meant to be cut out.
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